10 steps for optimising valve terminals. Handy hints for pneumatics, electrics & networking
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- Damian Howard
- 5 years ago
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1 10 steps for optimising valve terminals Handy hints for pneumatics, electrics & networking
2 The facts surrounding optimum TCO 10% 90% Customers are always looking for optimum performance and maximum efficiency, preferably combined with minimum costs. Anyone who has to worry about the total cost of ownership (TCO) of a system will know that the pure component costs may well account for only a very small proportion. The remaining costs are often not as obvious. Planning foresight can therefore play a key role in reducing total costs also in the case of pneumatics, electrics & networking. visible costs hidden costs This guide contains specific tips on how to get the most out of your budget and thus cut costs. 2 3
3 1. Achieve a reduction in ROI: Improved concepts for decentralisation and maintenance 10 tips for optimisation Page 1. Achieve a reduction in ROI: 5 Improved concepts for decentralisation and maintenance 2. Optimise cycle time by up to 30%: 6 System optimisation through simulation 3. Cut flow rate by up to 50%: 7 Decentralised concept 4. Optimise machine usage: 8 New diagnostic features and strategies 5. Reduce installation space by up to 70%: 10 Three possibilities 6. Increase efficiency by up to 60%: 11 Function integration 7. Cut costs by up to 50%: 12 Central installation with valve and I/O optimisation 8. Increase performance while reducing price 13 by up to 40%: More highly integrated I/O modules 9. Cut overhead costs by up to 34%: 14 Decentralised valve terminal in CPI system MPA 10. Decrease number of protection classes and ports: 15 Concepts for protected installation space/ control cabinet Costs Engineering Phases Savings potential Procurement Help minimise your total cost of ownership (TCO) by reducing cycle times by 5 or 10%, whilst increasing productivity. This formula for a decentralised machine concept often pays off, as it often takes only a few weeks or months to break even (achieve a return on investment) with regard to the higher costs of pneumatics/electrical engineering. Assembly Operation New diagnostic concepts also contribute towards your competitiveness, not to mention the fact that they improve TCO for your end customers. To sum up, you can enjoy reduced downtime, for instance through channel-oriented diagnosis, as well as increased machine availability thanks to condition monitoring and optional preventive maintenance. An option that is attractive for larger companies is remote maintenance, which opens up entirely new prospects for service concepts, maintenance, and the structuring of guarantees or maintenance contracts. 4 5
4 2. Optimise cycle time by up to 30%: System optimisation through simulation 3. Cut flow rate by up to 50%: Decentralised concept The cycle time for a pneumatic control chain depends on several factors, such as flow rate, tubing cross section and length, valve response time, and also properties of the drive and cushioning. Precise results can be obtained through simulation. The table below lists sample parameters, indicating when fast valves are more important and when a higher flow rate is required. Short-stroke cylinder ADN Standard cylinder DNC Valve type CPE10 MH2 MH3 MH4 Flow rate [l/min] Valve response [ms] time Costs [%] Cycle time [ms] ADN-32-5 [%] Result Same price but 10% more expensive 20% more expensive 30% more efficient but 40% more effi- but 40% more efficient cient Cycle time [ms] DNC [%] Result Same price, 10% more expensive, 20% more expensive, 154 % slower 32 % slower 23 % more efficient CPX-CP-Interface interface Ventilinsel Valve terminal Flow Durchfluss: rate: 340 l/min Valve Ventilinsel terminal CPV-SC (decentralized) (dezentral) Examine your installation. Can small valve terminals be mounted near the application? Can they be mounted on moving handling modules or robots? Tubing Schlauchlänge: 3 m lengh:0.3 Schlauchlänge: Tubing lengh:0.3 m0,3 m Flow Durchfluss: rate: 170 l/min Actuator Aktuator Flow Durchfluss: rate: 170 l/min Actuator Aktuator The illustration shows a possible configuration, where all valve terminals can be mounted on moving parts, and cables suitable for chain link trunking are available for both multi-pin plug and fieldbus connections. Look into the matter and speak to your specialists at Festo! Tubing type Internal-ø Maximum Loss Loss Loss designation [mm] flow rate after 1 m after 2 m after 5 m PUN-4x % 63 % 76 % PUN-6x % 57 % 73 % PUN-8x , % 60 % 74 % PUN-10x , % 50 % 67 % PUN-12x , % 48 % 65 % 6 7
5 4. Optimise machine usage: New diagnostic features and strategies Keywords for maximum performance and process reliability include an optimised approach to strategic diagnosis, diagnosis using various methods and selectable depth of diagnosis. For example: Increased depth of diagnosis: channel-oriented Downtime can be reduced by up to 8 times as a result of precise error detection for I/Os and valves. At the same time, you can enjoy increased reliability thanks to features such as the monitoring of a short circuit, or open load in the event of an interruption in an electrical connection or solenoid coil. New depth of diagnosis: integrated The new second-level and third-level diagnosis methods for the valve terminal MPA are more reliable, safer and more economical. New electrical modules that have serial internal linking, special Festo valve ASICs and software expertise can be used, for instance, to monitor the switching operation of the pilot control by analysing the solenoid coil s control current. One other thing that is new is pressure monitoring using integrated pressure sensors, which report the pressure on the MPA or from the process. Condition monitoring systems (CMS): foresighted CMS prevents downtime by means of precautionary measures, such as preventive maintenance for a valve, drive unit, sensors or the connected mechanics. End-to-end CMS for valves complete with preprocessing in the valve terminal is only available from Festo. Yet another benefit is that you no longer overlook maintenance and service intervals, and can transfer them to production-free or low-production times. CPX Web Monitor: comprehensive CPX Web Monitor is a comprehensive solution that provides top technological performance and is nevertheless simple to use for Festo plug and work. Without any programming effort, error messages and both digital and analogue process parameters are visible in standard browsers. The solution is an optional extra for all valve terminals connected to CPX via an Ethernet connection (CPX-FEC, FB32, FB33). What s more, a wide range of IT services are included, such as SMS or alerts, data transfer for statistical analyses, and visualisation of status and parameter signals. A live demo is provided at 8 9
6 5. Reduce installation space by up to 70%: Three possibilities 6. Increase efficiency by up to 60%: Function integration 1. Centralised or decentralised valves and I/O modules As a rule of thumb, the closer to the application, the smaller the amount of space that is needed. For example, up to 70% can be saved by using CPV-SC with multi-pin Sub-D plug rather than CPA10 (see point 3). This is also true in electrical terms, as a multi-pin plug connection may take up less space than a fieldbus connection. A potential space saving of up to 40% can therefore be made! 2. 50% reduction in space thanks to improved I/O modules with more channels per module 8DI rather than 4DI 16DI rather than 8DI 8DO rather than 4DO 4AI rather than 2AI 3. Choice of decentralised I/O modules from a triple platform saves space Compact takes up minimum space Sturdy aluminium housing, metal thread Economical high channel density Integrating functions saves space, simplifies mounting, commissioning and programming, and greatly reduces the costs involved in these tasks. Modules for temperature recording, manual pressure regulators, pressure sensors or proportional valves can now be ordered fully integrated into CPX/MPA, pre-fitted, parameterised and tested
7 7. Cut costs by up to 50%: Central installation with valve and I/O optimisation 8. Increase performance while reducing channel price by up to 40%: More highly integrated I/O modules The concentration of numerous valves and I/Os at a single point leads to savings. Examples for CPX/VTSA on Ethernet IP: for 4 5/2 valves 100% for 8 5/2 valves 28% reduction for 16 5/2 valves 40% reduction for 32 5/2 valves 50% reduction Examples for CPX/MPA on Profibus: for 16 3/2 valves 100% for 32 3/2 valves 16% reduction for 64 3/2 valves 24% reduction for 128 3/2 valves 28% reduction Examples: 8DI rather than 4DI: 40% reduction 16DI rather than 8DI: 25% reduction 8DO rather than 4DO: 15% reduction 4AI rather than 2AI: 20% reduction Channel price comparison 100 % 28 % 40 % 50 % Costs 4 valves 8 valves 16 valves 32 valves 12 13
8 9. Cut overhead costs by up to 34%: Decentralised valve terminal, type MPA, in CPI system 10. Decrease number of protection classes and connections: Concepts for protected installation space/ control cabinet This is achieved through a high number of I/Os per module, supplemented by highly economical I/O modules. The advantages of decentralised machine concepts, including maximum performance, unlimited modularity and extremely flexible networking, can at last be consistently combined with MPA. In fact, they can even be combined with those of a central concept, thanks to an MPA interface in the CPI installation system. Examples: IP20 CageClamp connection technology for the control cabinet flexible, reliable and fast Individual wiring or multipin plug in the control cabinet to reduce hardware costs Pneumatic multi-pin plug for CPV extremely spacesaving, both in the control cabinet and in the field Direct CageClamp machine mounting in IP20; cover for CPX accomodates IP65/
9 This checklist is merely a guide, because only those can optimise who know where the hidden potential is. Further information can be found in our All systems running brochure, and in our valve terminal system overview, both of which we would be happy to send to you. For details of specific optimisation methods, please consult your technical consultants, who will be delighted to help. Festo AG & Co. KG Ruiter Strasse Esslingen Germany Phone +49/711/347-0 Fax +49/711/ service_international@festo.com EN0702